Fall mat with hinged interlocking bodies

ABSTRACT

Disclosed herein is a fall mat that includes a first padded body including a first top surface, a first bottom surface, and a first connecting side including a first step. The fall mat further includes a second padded body including a second top surface, a second bottom surface, and a second connecting side including a second step. Moreover, the fall mat includes a hinge connecting the first padded body with the second padded body such that the second padded body is configured to rotate about the first padded body. The first step and the second step interlock when the first top surface and the second top surface of the first padded body and the second padded body are in a co-planar position.

FIELD OF THE TECHNOLOGY

The subject matter disclosed herein relates to fall mats for rock climbing. More particularly, the subject matter relates to a fall mat with hinged interlocking bodies that is foldable for easy transportation and storage.

BACKGROUND

Fall mats, also referred to as bouldering mats or crash pads, are used for rock climbing to prevent serious injury when a climber falls from a boulder or rock wall. Fall mats are often used to cover dangerous sections of the ground below a chosen climb such as protruding rocks or grass tufts. Fall mats typically cover about a three feet by four feet area beneath a climber and are three to five inches thick. Fall mats may be foldable once along a seam in order to reduce the transportation and storing dimensions to about three feet by two feet by ten inches. A typical fall mat utilizes two layers of foam in order to provide different levels of support. The upper layer of foam is generally higher in density than the lower level of foam. This prevents a climber's foot from sinking through the foam and either gaining impact on the floor or getting a foot stuck in the crash pad which would increase the chance of injury. To transport a fall mat, a climber typically folds the mat in half. Some fall mats include a crease or hinge to accommodate folding. However, rocks, roots or other ground protrusions are capable of penetrating into the crease or hinge during use such that very little padding is between a falling climber and the ground protrusion. This is potentially dangerous for a falling climber.

Thus, a fall mat with hinged interlocking bodies that is foldable for easy transportation and storage would be well received in the art.

BRIEF DESCRIPTION

According to one aspect, a fall mat comprises: a first padded body including a first top surface, a first bottom surface, and a first connecting side including a first step; a second padded body including a second top surface, a second bottom surface, and a second connecting side including a second step; and a hinge connecting the first padded body with the second padded body such that the second padded body is configured to rotate about the first padded body, wherein the first step and the second step interlock when the first top surface and the second top surface of the first padded body and the second padded body are in a co-planar position.

According to another aspect, a fall mat comprises: a first padded body having a first top surface and a first bottom surface, and a first connecting side, wherein a cross section of the first connecting side has an inverted step profile; a second padded body having a second top surface and a second bottom surface, and a second connecting side, wherein a cross section of the second connecting side has a step profile that corresponds to the inverted step profile of the first connecting side of the first padded body such that a substantial portion of the first connecting side and the second connecting side abut; and a hinge connecting the first padded body to the second padded body such that the second padded body is configured to rotate about the first padded body.

According to another aspect, a fall mat comprises: a first padded body having a first outer envelope surrounding a first top pad and a first lower pad, the first lower pad extending on a first connecting side a greater distance than the first top pad to create a first step; and a second padded body having a second outer envelope surrounding a second top pad and a second lower pad, the second top pad extending on a second connecting side a greater distance than the second lower pad to create a second step; wherein the first outer envelope and the second outer envelope are connected between the first connecting side and the second connecting side such that the first padded body is rotatable about the second padded body.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 depicts a perspective view of a fall mat set up under a climber in accordance with one embodiment;

FIG. 2 depicts a perspective view of the fall mat of FIG. 1 with a first body rotated about an interlocking hinge with respect to a second body in accordance with one embodiment;

FIG. 3 depicts a cutaway view of the fall mat of FIGS. 1-2 in an open position in accordance with one embodiment;

FIG. 4 depicts a cross sectional side view of the fall mat of FIGS. 1-3 in an open position taken at arrows 4-4 in accordance with one embodiment; and

FIG. 5 depicts a perspective view of a fall mat in accordance with another embodiment.

DETAILED DESCRIPTION

A detailed description of the hereinafter described embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

Referring first to FIGS. 1-4, a fall mat 10 is shown. The fall mat 10 may also be referred to as a bouldering mat, a crash pad, or the like. Whatever the embodiment, the fall mat 10 may be configured to break the fall of a climber 12 that falls from a boulder 14 or other climbing surface, as shown in FIG. 1. The fall mat 10 includes a first padded body 16 and a second padded body 18. The first padded body 16 includes a first top surface 20 facing the climber 12 when in use, and a first bottom surface 22 facing the ground 24. The second padded body 18 also includes a second top surface 21 facing the climber when in use, and a second bottom surface 23 facing the ground. The fall mat 10 includes a hinge 26 that allows the fall mat 10 to fold for easy transportation and storage, as shown in FIG. 2. The hinge 16 connects the first padded body 16 and the second padded body 18 at respective first and second connecting sides 28, 30. The first connecting side 28 of the first padded body 16 includes a first step 32. Likewise, the second connecting side 30 of the second padded body 18 includes a second step 34. The first and second steps 32, 34 interlock when the top surfaces 20, 21 and the bottom surfaces 22, 23 of the first padded body 16 and the second padded body 18 are in a co-planar position, as shown in FIG. 1. Because of the stepped interlocking nature of the padded bodies 16, 18, the fall mat 10 may be configured to prevent rocks, roots, or other ground protrusions from penetrating into the crease up to the hinge 26. Thus, there may always be padding between the falling climber 12 and the ground 24 or any ground protrusions extending therefrom.

The first padded body 16 and the second padded body 18 may each be enveloped by an outer envelope 36 that includes a top cover 38. The top cover 38 may comprise a different and more robust material than the rest of the outer envelope 36. For example, the top cover 38 of the outer envelope 36 may comprise a thousand denier Cordura® nylon. This is meant to be exemplary, and more or less denier nylon may be utilized. Further, other embodiments may use other material other than nylon. The rest of the cover 38 may comprise a brazen resistant nylon of a lower denier count. Further, corners 40 of the outer envelope 36 may be reinforced by higher denier nylon, like the cover 38. This may protect the fall mat 10 and increase the durability by reinforcing the areas that are likely to break down and wear out from use.

Shown in FIGS. 3-4, within the outer envelope 36 of the first padded body 16 is a first top pad 42, a first middle pad 44, and a first bottom pad 46. Likewise, within the outer envelope 36 of the second padded body 18 is a second top pad 43, a second middle pad 45, and a second bottom pad 47. The top pads 42, 43 the middle pads 44, 45 and the bottom pads 46, 47 may each be made of a foam material, for example. The top pads 42, 43 and the bottom pads 46, 47 may each be made of the same material in one embodiment. The top pads 42, 43 and the bottom pads 46, 47 for example, may be made from closed cell polyethylene foam. The top pads 42, 43 and bottom pads 46, 47 may be made from relatively hard foam having a high-density, for example over 2 pounds per cubic foot. In one embodiment, the density range may be between 1.8 pounds per cubic foot to 3.0 pounds per cubic foot. The high density of the top pads 42, 43 may prevent a climber's foot from sinking into the fall-mat 10 and impacting protrusions from the ground 24 that may be felt on a fall. The middle pads 44, 45 may be made from softer foam than the top pads 42, 43 and the bottom pads 46, 47. For example, the middle pads 44, 45 may be made from an open cell softer polyurethane foam. The softer foam of the middle pads 44, 45 may be less dense. For example, the softer foam may have a density of 1.8 pounds per cubic feet. In one embodiment, the density range of the polyurethane foam may be between 1.0 pounds per cubic foot to 2.5 pounds per cubic foot. Further, the middle layer may have an ILD (impression load deflection) firmness between 40 and 80.

The top pads 42, 43 are thicker than the bottom pads 46, 47 in the embodiment depicted. However, this embodiment is not limiting, and the thicknesses of the pads 42, 43, 44, 45, 46, 47 may vary. For example, the top pads 42, 43 may have a 1 inch thickness, the middle pads 44, 45 may have a 3 inch thickness and the bottom pads 46, 47 may have a 0.5 inch thickness in one embodiment. Further, the top pads 42, 43 may have a thickness between 0.25 inches-1.5 inches, the middle pads 44, 45 may have a thickness between 1 inch and 4 inches, and the bottom pads 46, 47 may have a thickness between 0 inches and 1 inch.

It is also possible to change the arrangement of the layers. In one embodiment, for example, it is possible to add a thin layer of soft polyurethane foam above the top pads 42, 43. Another embodiment may include softer open cell polyurethane foam on top, with a middle pad of denser closed cell polyethelene foam, with a bottom pad of softer open cell polyurethane foam. Still another embodiment may include a top layer of closed cell polyethylene foam, a second layer of softer open cell polyurethane foam, with a third layer of closed cell polyethylene foam, a fourth layer of softer open cell polyurethane foam, and a fifth lowest layer of closed cell polyethylene foam. These options are meant to be exemplary, as many more embodiments that would be apparent to those skilled in the art are contemplated.

In other embodiments, the fall mat 10 may not include the bottom pads 46, 47. Instead the fall mat 10 may only include two layers. In this embodiment, the middle pads 44, 45 may be referred to as a “lower pad,” as there would be no other layer under the middle pads 44, 45 and the middle pads 44, 45 are still lower than the top pads 42, 43. Other embodiments are also contemplated having more than three layers. Any internal layering of material may be appropriate. Furthermore, the pads 42, 43, 44, 45, 46, 47 may be made of other materials than foam. For example, the pads 42, 43, 44, 45, 46, 47 may be made of any soft, elastic, resilient material that would cushion a falling bouldering rock climber, such as the climber 12.

The pads 42, 43, 44, 45, 46, 47 may be joined together within the outer envelope 36 by hook and loop fastener or the like. In other embodiments, the pads 42, 43, 44, 45, 46, 47 may be joined together with a glue or epoxy. However, it is also possible that the pads 42, 43, 44, 45, 46, 47 are not joined together with any adjoining means, but instead held into place by the tightness of the outer envelope 36 surrounding the pads 42, 43, 44, 45, 46, 47.

The hinge 26 of the fall mat 10 connects the first padded body 16 and the second padded body 18 at the top surfaces 20, 21. The connection at the top surfaces 20, 21 may be optimal in order to prevent a climber from slipping between the crack if there was an opening between the first top surface 20 and the second top surface 21. The hinge 26 may comprise a strip of material connecting the first and second padded bodies 16, 18 along the length of the first and second connecting sides 28, 30. In one embodiment, the hinge 26 may include additional reinforcing nylon 48 stitched between the top surfaces 20, 21 of the fall mat 10. The reinforcing nylon 48 may run the entire length of the hinged seam. While the strip 48 may be nylon, other fabric materials are contemplated. Furthermore, the hinge 26 may be reinforced internally by a strip of polyester seatbelt webbing material 50. The hinge 26 may allow the first and second padded bodies 16, 18 to rotate with respect to each other. Thus, the hinge 26 may allow the fall mat 10 to achieve both an in-use co-planar configuration as shown in FIG. 1, and a transportation and storage configuration as shown in FIG. 2. In the transportation and storage configuration, the top surfaces 20, 21 of both the first and second padded bodies 16, 18 may be rotated so that they face each other. While the hinge 26 is shown between the top surfaces 20, 21, in other embodiments, the hinge 26 may be located between the bottom surfaces 22, 23. In this embodiment, first and second padded bodies 16, 18 may be rotated such that the bottom surfaces 22, 23 face each other.

In the in-use configuration, the fall mat 10 may be unfolded such that the first padded body 16 and the second padded body 18 are co-planar. In this position, the hinge 26 is located at or close to the middle of the top surfaces 20, 21 facing the climber 12. Beneath the hinge 26, the first connecting side 28 and the second connecting side 30 come together such that a substantial portion or all of the first connecting side 28 and the second connecting side 30 abut. In the embodiment depicted in the Figures, the first connecting side 28 has an inverted step profile and the second connecting side 30 has a step profile. These steps 32, 34 are correspondingly adjacent, abutting, and interlocking when the fall mat 10 is in the in-use, co-planar configuration.

The first inverted steps 32 is shown with substantially perpendicular edges, having a first vertical edge 52, a second vertical edge 56, and an intermediary horizontal edge 60 that is between the first and second vertical edges 52, 56. The second step 34 is shown also with substantially perpendicular edges, having a first vertical edge 54 corresponding with and abutting the first vertical edge 52, a second vertical edge 58 corresponding with an abutting the second vertical edge 56, and a horizontal edge 62 corresponding with and abutting the horizontal edge 60.

As shown in FIGS. 3-4, first vertical edges 52, 54 extend a vertical distance that corresponds with the vertical height of the first and second top pads 42, 43. The second vertical edges 56, 58 extend a vertical distance that corresponds with the vertical height of the first and second middle pads 44, 45 and first and second bottom pads 46, 47. In other words the second top pad 43 of the second padded body 18 extends on the second connecting side a greater distance than the second middle pad 45 and the second bottom pad 47 to create the second step 34. Likewise, the first middle pad 44 and the first bottom pad 46 extend on the first connecting side a greater distance than the first top pad 42 to create the first inverted step 32.

The perpendicular edges of the steps 32, 34 prevent roots, rocks or other ground protrusions from protruding into the space between the first connecting side 28 and the second connecting side 30 all the way to the top surface 20. No matter what the size of the ground protrusion, at least the first and second top pads 42, 43 will remain between the ground protrusion and the falling climber.

Referring now to FIG. 5, another embodiment of a fall mat 100 is shown. The fall mat 100 may be similar to the fall mat 10. Thus, the fall mat 100 may include a first padded body 116 and a second padded body 118, and a first connecting side 128 and a second connecting side 130. Internally, the fall mat 100 may include top pads, middle pads, and bottom pads (not shown) similar to the fall mat 10. However, unlike the fall mat 10, the first and second connecting sides 128, 130 have a different stepped and interlocking shape. The first connecting side 128 is shown having a first vertical edge 152, a first horizontal edge 154, a second vertical edge 156, a second horizontal edge 158, and a third vertical edge 160. Likewise, the second connecting side 130 is shown having a first vertical edge 153, a first horizontal edge 155, a second vertical edge 157, a second horizontal edge 159, and a third vertical edge 161. The first vertical edges 152, 153 are correspondingly abutting in the in-use position shown in the Figure. Likewise, the first horizontal edges 154, 155 are correspondingly abutting, the second vertical edges 156, 157 are correspondingly abutting, the second horizontal edges 158, 159 are correspondingly abutting, and the third vertical edges 160, 161 are correspondingly abutting. The first connecting side 128 is shown having a generally U-shaped stepped profile, while the second connecting side 130 is shown having a corresponding T-shaped profile that is configured to interlock with the first connecting side 128. It should be understood that internal top pads (not shown) may correspond with the first vertical edges 152, 153 similar to the embodiment described hereinabove. Likewise, internal middle pads (not shown) may correspond with the second vertical edges 156, 157 and internal bottom pads (not shown) may correspond with the third vertical edges 160, 161.

Elements of the embodiments have been introduced with either the articles “a” or “an.” The articles are intended to mean that there are one or more of the elements. The terms “including” and “having” and their derivatives are intended to be inclusive such that there may be additional elements other than the elements listed. The conjunction “or” when used with a list of at least two terms is intended to mean any term or combination of terms. The terms “first” and “second” are used to distinguish elements and are not used to denote a particular order.

While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. 

1. A fall mat comprising: a first padded body including a first top surface, a first bottom surface, and a first connecting side including a first step; a second padded body including a second top surface, a second bottom surface, and a second connecting side including a second step; and a hinge connecting the first padded body with the second padded body such that the second padded body is configured to rotate about the first padded body, wherein the first step and the second step interlock when the first top surface and the second top surface of the first padded body and the second padded body are in a co-planar position.
 2. The fall mat of claim 1, wherein the first padded body includes a first top pad, a first middle pad, and a first bottom pad, wherein the second padded body includes a second top pad, a second middle pad, and a second bottom pad.
 3. The fall mat of claim 2, wherein the first and second top and bottom pads are made of a denser material than the first and second middle pads.
 4. The fall mat of claim 2, wherein the first top pad of the first padded body extends on the first connecting side a greater distance than the first middle pad and the first bottom pad to create the first step, and wherein the second bottom pad and second middle pad of the second padded body extends on the second connecting side a greater distance than the second top pad to create the second step.
 5. The fall mat of claim 1, wherein the hinge is a length of material that connects the first and second top surfaces of the first padded body and the second padded body.
 6. The fall mat of claim 5, wherein the first padded body is enclosed by a first envelope and where the second padded body is enclosed by a second envelope, the first and second envelopes are connected at the hinge.
 7. The fall mat of claim 6, wherein a length of polyester seatbelt webbing material is located within the first envelope and the second envelope under the hinge, the length of polyester seatbelt webbing material configured to reinforce the hinge.
 8. The fall mat of claim 1, wherein the first top surface of the first padded body is rectangular in shape, and wherein the second top surface of the second padded body is rectangular in shape.
 9. The fall mat of claim 1, wherein the first step extends along the entire length of the first connecting side, and wherein the second step extends along the entire length of the second connecting side.
 10. A fall mat comprising: a first padded body having a first top surface and a first bottom surface, and a first connecting side, wherein a cross section of the first connecting side has an inverted step profile; a second padded body having a second top surface and a second bottom surface, and a second connecting side, wherein a cross section of the second connecting side has a step profile that corresponds to the inverted step profile of the first connecting side of the first padded body such that a substantial portion of the first connecting side and the second connecting side abut; and a hinge connecting the first padded body to the second padded body such that the second padded body is configured to rotate about the first padded body.
 11. The fall mat of claim 10, wherein the first padded body includes a first top pad, a first middle pad, and a first bottom pad, wherein the second padded body includes a second top pad, a second middle pad, and a second bottom pad.
 12. The fall mat of claim 11, wherein the first and second top and bottom pads are made of a denser material than the first and second middle pads.
 13. The fall mat of claim 12, wherein the first top pad of the first padded body extends on the first connecting side a greater distance than the first bottom pad and the first middle pad to create first step, and wherein the second bottom pad and second middle pad of the second padded body extends on the second connecting side a greater distance than the second top pad to create the second step.
 14. The fall mat of claim 10, wherein the hinge is a length of material that connects the top surfaces of the first padded body and the second padded body.
 15. The fall mat of claim 14, wherein the first padded body is enclosed by a first envelope and where the second padded body is enclosed by a second envelope, the first and second envelopes are connected at the hinge.
 16. The fall mat of claim 15, wherein a length of polyester seatbelt webbing material is located within the first envelope and the second envelope under the hinge, the length of polyester seatbelt webbing material configured to reinforce the hinge.
 17. The fall mat of claim 10, wherein the first top surface of the first padded body is rectangular in shape, and wherein the second top surface of the second padded body is rectangular in shape.
 18. The fall mat of claim 10, wherein the inverted step profile extends along the entire length of the first connecting side, and wherein the step profile extends along the entire length of the second connecting side.
 19. A fall mat comprising: a first padded body having a first outer envelope surrounding a first top pad and a first lower pad, the first lower pad extending on a first connecting side a greater distance than the first top pad to create a first step; and a second padded body having a second outer envelope surrounding a second top pad and a second lower pad, the second top pad extending on a second connecting side a greater distance than the second lower pad to create a second step; wherein the first outer envelope and the second outer envelope are connected between the first connecting side and the second connecting side such that the first padded body is rotatable about the second padded body.
 20. The fall mat of claim 19, wherein the first padded body includes a first top surface and a first bottom surface and wherein the second padded body includes a second top surface and a second bottom surface, and wherein the first step is an inverted step, and wherein the first step and the second step interlock when first and second top and bottom surfaces of the first padded body and the second padded body are co-planar. 